US10511013B2 - Electrochemical cell with protected negative electrode - Google Patents

Electrochemical cell with protected negative electrode Download PDF

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US10511013B2
US10511013B2 US15/512,480 US201515512480A US10511013B2 US 10511013 B2 US10511013 B2 US 10511013B2 US 201515512480 A US201515512480 A US 201515512480A US 10511013 B2 US10511013 B2 US 10511013B2
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layer
conducting material
ion conducting
substrate
alkali metal
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US20170279108A1 (en
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Subramanya P. HERLE
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Elevated Materials Us LLC
Elevated Materials Germany GmbH
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Applied Materials Inc
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0402—Methods of deposition of the material
    • H01M4/0404—Methods of deposition of the material by coating on electrode collectors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0438—Processes of manufacture in general by electrochemical processing
    • H01M4/044—Activating, forming or electrochemical attack of the supporting material
    • H01M4/0442—Anodisation, Oxidation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0438—Processes of manufacture in general by electrochemical processing
    • H01M4/044—Activating, forming or electrochemical attack of the supporting material
    • H01M4/0445—Forming after manufacture of the electrode, e.g. first charge, cycling
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0438—Processes of manufacture in general by electrochemical processing
    • H01M4/045—Electrochemical coating; Electrochemical impregnation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H01M4/1395—Processes of manufacture of electrodes based on metals, Si or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
    • H01M4/381—Alkaline or alkaline earth metals elements
    • H01M4/382—Lithium
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/66—Selection of materials
    • H01M4/665—Composites
    • H01M4/667—Composites in the form of layers, e.g. coatings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/70—Carriers or collectors characterised by shape or form
    • H01M4/72—Grids
    • H01M4/74—Meshes or woven material; Expanded metal
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M2004/026—Electrodes composed of, or comprising, active material characterised by the polarity
    • H01M2004/027—Negative electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0402—Methods of deposition of the material
    • H01M4/0421—Methods of deposition of the material involving vapour deposition
    • H01M4/0423—Physical vapour deposition
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0471—Processes of manufacture in general involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • Embodiments of the present disclosure relate generally to electrochemical cells, and more specifically, although not exclusively, to protected negative electrodes.
  • a common mode of failure for lithium-based batteries is the growth of lithium dendrites which may grow to short the battery electrodes.
  • the present disclosure describes an electrochemical energy storage device, such as a battery, comprising a positive electrode and a negative electrode separated by a separator and an electrolyte which acts as an ionic conductive matrix, wherein the negative electrode is configured to reduce or eliminate the occurrence of alkali metal dendrite formation.
  • the negative electrode may be fabricated with a densified ion conducting material which acts as the separator.
  • the negative electrode may be configured as a protected alkali metal electrode.
  • a method of fabricating a negative electrode for an electrochemical cell may comprise: providing a substrate, the substrate being electrically conductive; depositing a metal layer on the substrate; anodizing the metal layer to form a porous layer on the substrate; depositing a layer of ion conducting material on the porous layer, the layer of ion conducting material extending at least partially into pores of the porous layer; densifying the layer of ion conducting material; depositing a layer of alkali metal on the densified layer of ion conducting material; attaching a temporary electrode to the layer of alkali metal and passing a current between the temporary electrode and the substrate to drive alkali metal through the densified layer of ion conducting material to the surface of the substrate, forming an alkali metal reservoir at the surface of the substrate.
  • a method of fabricating a negative electrode for an electrochemical cell may comprise: providing an electrically conductive mesh; depositing a layer of ion conducting material on the electrically conductive mesh, the layer of ion conducting material extending at least partially into holes of the electrically conductive mesh; densifying the layer of ion conducting material; depositing a layer of alkali metal on the densified layer of ion conducting material; and attaching a temporary electrode to the layer of alkali metal and passing a current between the temporary electrode and the electrically conductive substrate to drive alkali metal through the densified layer of ion conducting material to the surface of the electrically conductive mesh, forming an alkali metal reservoir at the surface of the electrically conductive mesh.
  • a method of fabricating a negative electrode for an electrochemical cell may comprise: providing an electrically conductive substrate; depositing a layer of ion conducting material on the electrically conductive substrate; densifying the layer of ion conducting material; depositing a layer of alkali metal on the densified layer of ion conducting material; and attaching a temporary electrode to the layer of alkali metal and passing a current between the temporary electrode and the electrically conductive mesh to drive alkali metal through the densified layer of ion conducting material to the surface of the electrically conductive substrate, forming an alkali metal reservoir at the surface of the electrically conductive substrate.
  • FIGS. 1-5 are schematic cross-sectional representations of a first negative electrode fabrication process, according to some embodiments.
  • FIGS. 6-11 are schematic cross-sectional representations of a second negative electrode fabrication process, according to some embodiments.
  • FIG. 12 shows the structure of FIG. 11 after movement of lithium metal to the substrate when porous layer 203 is a lithium ion conductor, according to some embodiments;
  • FIG. 13 shows the structure of FIG. 11 after movement of lithium metal to the substrate when porous layer 203 is not a lithium ion conductor, according to some embodiments;
  • FIGS. 14 & 15 are schematic cross-sectional representations of a third negative electrode fabrication process, according to some embodiments.
  • FIG. 16 is a schematic cross-sectional representation of a further negative electrode structure, according to some embodiments.
  • the present disclosure describes an electrochemical energy storage device, such as a battery, comprising a positive electrode and a negative electrode separated by a separator and an electrolyte which acts as an ionic conductive matrix, wherein the negative electrode is configured to reduce or eliminate the occurrence of lithium metal dendrite formation. Furthermore, the negative electrode may be configured as a protected lithium electrode.
  • FIGS. 1-3 show the fabrication of a first embodiment of a negative electrode.
  • a substrate 101 which can also be a current collector formed of, for example, copper, stainless steel, or a dielectric material such as glass coated with electrically conductive material, is provided.
  • a dielectric material such as glass coated with electrically conductive material
  • a deposition technique such as PVD, plasma spray, thermal spray, green tape deposition, etc.
  • the ion conducting material is densified to form a densified ion conducting material 103 , using a method such as firing, sintering, laser or furnace annealing, RTP, etc.
  • the densified ion conducting material should be free of pinholes or has high aspect ratio pores to inhibit dendrite growth.
  • the negative electrode shown in FIG. 3 may be taken and combined with a positive electrode, which may in embodiments be deposited directly on the negative electrode.
  • the densified ion conducting material 103 on the negative electrode acts as an ion conducting separator in the resulting battery. In this embodiment the lithium metal comes from the positive electrode.
  • the positive electrode can be printed/coated on an Al current collector with or without liquid electrolyte and the active material can be blended with Li-conducting solid electrolyte to reduce the liquid electrolyte in the positive electrode.
  • the electrochemical cell assembly may have reduced liquid electrolyte on the positive electrode and on the negative electrode side there is no liquid electrolyte.
  • the positive electrode may be patterned to reduce tortuosity and obtain higher charge rate performance.
  • FIGS. 4-5 the processing of the negative electrode of FIG. 3 may be continued as shown in FIGS. 4-5 .
  • lithium metal 104 is deposited on the densified ion conducting material 103 .
  • the lithium metal deposition area is made smaller than the area of the surface of the ion conducting material on to which it is deposited the lithium metal is kept away from the edges.
  • a temporary electrode (not shown), formed of copper for example, is attached to the lithium covered top surface of the densified ion conducting material so that a current may be passed between the temporary electrode and the substrate/current collector so as to drive the lithium 104 through the densified ion conducting material 103 to the surface of the substrate/current collector 101 where a lithium reservoir 105 is formed.
  • a mixed ionically and electrically conductive oxide can be deposited in between the layer of densified ion conducting material and the layer of lithium metal so that all of the lithium can be effectively moved electrochemically to the interface between the substrate and the densified ion conducting material.
  • the negative electrode of FIG. 5 may be taken and combined with a positive electrode, such as described above, to form a battery.
  • the lithium reservoir is protected being separated from the surface of the negative electrode by a layer of ion conducting material which may be effective in protecting the lithium from oxidizing elements/compounds in the environment, which makes handling of the negative electrode easier.
  • a negative electrode for an electrochemical cell may comprise: an electrically conductive substrate; a densified layer of ion conducting material on the electrically conductive substrate; a layer of alkali metal on the densified layer of ion conducting material; and an alkali metal reservoir at the surface of the electrically conductive substrate, the alkali metal reservoir having been formed by attaching a temporary electrode to the layer of alkali metal and passing a current between the temporary electrode and the electrically conductive substrate to drive alkali metal through the densified layer of ion conducting material to the surface of the electrically conductive substrate.
  • FIGS. 6-11 show the fabrication of a second embodiment of a negative electrode.
  • a substrate 201 which can also be a current collector formed of, for example, copper, stainless steel, or a dielectric material such as glass coated with electrical conductive material, is provided.
  • the substrate is coated with a metal 202 suitable for forming a porous layer, such as aluminum, zirconium or titanium; the coating may be deposited on one or both sides of the substrate, and may be deposited using a deposition technique such as PVD.
  • the metal is anodized to form a porous layer 203 .
  • the pores may extend only part way or all the way through the thickness of the metal layer; the pores are typically nanometer scale (sub-10 s to 100 s of nanometers in diameter, in embodiments in the range of 10 nm to 500 nm), and may have either low or high density.
  • the porous layer is typically in the range of 1 to 10 microns thick and in embodiments 2 to 5 microns thick.
  • the coating 204 is deposited at least partially into the pores using PVD, thermal evaporation, thermal spray, e-beam evaporation, chemical solution deposition or chemical vapor deposition.
  • the ion conducting material is densified to form a densified ion conducting material 205 , using a method such as firing, sintering, laser or furnace annealing, RTP, etc.
  • the densified ion conducting material in embodiments is free of pinholes or has high aspect ratio pores to inhibit dendrite growth.
  • the negative electrode shown in FIG. 10 may be taken and combined with a positive electrode such as described above, which may in embodiments be deposited directly on the negative electrode; in this embodiment the lithium metal comes from the positive electrode.
  • FIGS. 11-13 the processing of the negative electrode of FIG. 10 may be continued as shown in FIGS. 11-13 .
  • lithium metal 206 is deposited on the densified ion conducting material 205 .
  • the lithium metal deposition area is made smaller than the area of the surface of the ion conducting material on to which it is deposited the lithium metal is kept away from the edges.
  • a temporary electrode (not shown), formed of copper for example, is attached to the lithium covered top surface of the densified ion conducting material so that a current may be passed between the temporary electrode and the substrate/current collector so as to drive the lithium 206 through the densified ion conducting material 205 to the surface of the substrate/current collector 201 where a lithium reservoir 207 / 208 is formed.
  • FIG. 12 shows the result for the embodiment in which the anodized metal is an ion conductor for example when the metal is zirconium or titanium, and the porous layer is formed of ZrO x or TiO x , respectively and FIG.
  • FIG. 13 shows the result for the embodiment in which the anodized metal is not an ion conductor, but for which lithium may move along the surface of the pores for example when the metal is aluminum and the porous layer is formed of Al 2 O 3 .
  • the negative electrode of FIG. 12 or 13 may be taken and combined with a positive electrode to form a battery. Note that in the embodiment of FIGS. 12 & 13 , the lithium reservoir is protected being separated from the surface of the negative electrode by a layer of ion conducting material which may be effective in protecting the lithium from oxidizing elements/compounds in the environment, which makes handling of the negative electrode easier.
  • a negative electrode for an electrochemical cell may comprise: a substrate, the substrate being electrically conductive; a porous anodized metal layer on the substrate; a densified layer of ion conducting material on the porous layer, the layer of ion conducting material extending at least partially into pores of the porous layer; a layer of alkali metal on the densified layer of ion conducting material; and an alkali metal reservoir at the surface of the substrate, the alkali metal reservoir having been formed, for example, by attaching a temporary electrode to the layer of alkali metal and passing a current between the temporary electrode and the substrate to drive alkali metal through the densified layer of ion conducting material to the surface of the substrate.
  • FIGS. 14-15 show the fabrication of a third embodiment of a negative electrode.
  • a substrate 301 formed of a mesh such as a glass fiber mesh, a ceramic fiber mesh or a polymer mesh, is provided.
  • a deposition technique such as PVD, plasma spray, thermal spray, green tape deposition, thermal evaporation, e-beam evaporation, chemical solution deposition or chemical vapor deposition, etc.
  • a thin layer of metal 303 such as copper metal is deposited on the back side of the mesh already coated on the other side with ion conducting material 302 .
  • This structure may then go through densification as described above and then be used as a negative electrode either with a without a lithium reservoir. Note that this embodiment provides a flexible electrode.
  • a method of fabricating a negative electrode for an electrochemical cell may comprise: providing a mesh, such as a glass fiber mesh, a ceramic fiber mesh or a polymer mesh; depositing a layer of ion conducting material on the front side of the mesh, the layer of ion conducting material extending at least partially into holes of the mesh; after the depositing the layer of ion conducting material, depositing a layer of metal on the back side of the mesh; densifying the layer of ion conducting material; depositing a layer of alkali metal on the densified layer of ion conducting material; and attaching a temporary electrode to the layer of alkali metal and passing a current between the temporary electrode and the layer of metal to drive alkali metal through the densified layer of ion conducting material to the surface of the layer of metal on the back side of the mesh, forming an alkali metal reservoir at the surface of the layer of metal.
  • an electrically conductive mesh may be used to replace the structure of FIG. 8 in the above fabrication process, although it should be noted that the holes in the mesh are typically micron-scale (sub-10 s to 100 s of microns in diameter, in embodiments in the range of one micron to one hundred microns) whereas the pores in the anodized metal are typically nanometer-scale.
  • a negative electrode for an electrochemical cell may comprise: an electrically conductive mesh; a layer of densified ion conducting material on the electrically conductive mesh, the layer of ion conducting material extending at least partially into holes of the electrically conductive mesh; a layer of alkali metal on the densified layer of ion conducting material; and an alkali metal reservoir at the surface of the electrically conductive mesh, the alkali metal reservoir having been formed, for example, by attaching a temporary electrode to the layer of alkali metal and passing a current between the temporary electrode and the electrically conductive mesh to drive alkali metal through the densified layer of ion conducting material to the surface of the electrically conductive mesh.
  • the electrically conductive mesh may comprise a mesh such as a glass fiber mesh, a ceramic fiber mesh or a polymer mesh, for example, coated with a layer of metal on the side of the mesh opposite to the layer of ion conducting material, as shown in FIG. 15 .
  • the negative electrodes with the porous substrate are expected to exhibit improved stress handling due to battery cycling (repeated movement of lithium to and from the negative electrode during charging and discharging cycles) when compared with negative electrodes without a porous substrate.
  • a method of fabricating an electrochemical cell may comprise depositing one or more metals, such as Al, on a separator 401 , such as a poly-olefin separator, and anodizing the layer of metal to form an anodized layer 402 with vertically aligned nanopores that inhibit dendrite growth, thus forming a protective sheet, and laminating this protective sheet to a lithium metal 403 coated current collector layer 404 , such as a copper layer, with the anodized metal facing the lithium.
  • a separator 401 such as a poly-olefin separator
  • the protective sheet can be coated with an ion conducting material 405 which is deposited at least partially into the pores (and the ion conducting material may be densified) prior to lamination, such that the ion conducting material is facing lithium, helping prevent dendrite formation.
  • the ion conducting material may be one or more of the ion conducting materials provided as examples for embodiments described above, and may be deposited and densified using methods and equipment as described above.
  • FIG. 16 shows the resulting negative electrode structure with the ion conducting material.
  • a method of fabricating a negative electrode for an electrochemical cell may comprise: providing a separator; depositing a metal layer on the separator; anodizing the metal layer to form a porous layer on the separator; depositing a layer of ion conducting material on the porous layer, the layer of ion conducting material extending at least partially into pores of the porous layer; densifying the layer of ion conducting material, forming a protective sheet; and laminating a current collector layer coated with a layer of alkali metal to the protective sheet, the alkali metal facing the densified ion conducting material.
  • the alkali metal is lithium.
  • a negative electrode for an electrochemical cell may comprise: a separator; a porous layer of anodized metal on said separator; a layer of densified ion conducting material on the porous layer, the layer of densified ion conducting material extending at least partially into pores of the porous layer; a layer of alkali metal on said densified ion conducting material; and a current collector on the layer of alkali metal.
  • the alkali metal is lithium.

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